Recycle alkylation process utilizing an electric field



March 29, 1966 E. A. COLE, JR

RECYCLE ALKYLATION PROCESS UTILIZING AN ELECTRIC FIELD Filed Sept. 17. 1963 3 Sheets-Sheet l HEZINVlnGBG March 29, 1966 E. A. COLE, JR

RECYCLE ALKYLATION PROCESS UTILIZING AN ELECTRIC FIELD Filed Sept. 17, 1965 3 Sheets-Sheet 2 HBZINVJJIGBO HBZINVdOHdEG HEZINVLOEOSIBCI HAV-m March 29, 1966 E. A. COLE, JR

RECYCLE ALKYLATION PROCESS UTILIZING AN ELECTRIC FIELD 5 Sheets-Sheet 5 Filed Sept. 17. 1965 HEZINVJJNEBG HBZINVLOEOSIEG HEIZINVdOHdBG United States Patent O 3 243,474 RECYCLE ALKYLATION PRGCESS UTILIZING AN ELECTRIC FIELD Ernest A. Cole, Jr., Houston, Tex., assignor to Petrolite Corporation, Wilmington, Del., a corporation of Delaware Filed Sept. 17, 1963, Ser. No. 309,471 8 Claims. (Cl. 260--683.46)

This invention relates to a process of alkylation. This invention also relates to a process of alkylating hydrocarbons to produce an alkylate used as an important constituent of high octance gasoline.

The advantages of this invention will become apparent from the description herein given 4and by examination of the drawings in which:

FIGURE I is a typical alkylation process flow sheet of the prior art.

FIGURE II is a representative alkylation process flow sheet employing an electric field as described in Samuelsons application Serial No. 174,735.

FIGURE III is a representative alkylation process flow sheet of the present invention.

Alkylation processes include the alkylation of parafins, isoparaflins, aromatic compounds, cycloaliphatic compounds, etc. with olens. The alkylation reaction may take place over a wide range of temperatures ranging from below F. when alkylating isoparafiins to as high as about 600 F. when certain aromatic compounds are reacted with olefins. It may be conveniently carried out under pressures at or below atmospheric or as high as several hundred atmospheres.

The major alkylation process in use today involves the reaction of isoparafhns with oleiins in the presence of an acid catalyst to form valuable high octane gasoline components. The isoparafiins used may be isobutane, isopentane, isohexane, etc., or mixtures thereof. Olefins more often reacted are propylenes, butylenes, pentylenes, their isomers, and mixtures thereof. In addition, one may utilize any proportions of the above as feed stocks as well as mixtures of isoparafiins and olefins with or without the presence of normal parains.

Various methods of preparing high octane alkylates by reacting olefins with paraflins, such as isoparafns, are known. These methods include liquid phase catalytic alkylations with (l) hydrogen fiuoride and (2) concentrated sulfuric acid. In general these methods are carried out by adding an olefin to an excess of an isoparaflin hydrocarbon emulsified in the catalyst. Excess isoparaiiin is separated after alkylation and recirculated. Sufficient pressure is employed during the process to keep the reactants in the liquid phase. Higher temperatures can be employed with HF, such as 70-ll5 F., but lower temperatures for example 30-50" F. `are employed with HZSO., to suppress side reactions.

In a typical commercial alkylation, isobutane and the acid catalyst are introduced into an alkylation reaction zone, and are violently agitated to -form an emulsion, this being the preferred method of assuring intimate contact between the acid catalyst and the hydrocarbon to be alkylated. Inasmuch as the reaction occurs at the liquidliquid interface, it is necessary to provide violent agitation and intimate contact if the desired reaction is to take place. The major portion of the isobutane feed is provided by a recycle stream obtained from subsequent distillation steps; any additional quantity of isobutane required, for example that amount needed to start up the unit, is usually supplied from an independent source. The agitation may be provided in a number of ways. Usually a conventional mixer or pump provides a means for creating `and moving the emulsion at high velocity and also for circulating the emulsion in the contact zone. The alkylation reaction may be carried out in one step, although 3,243,474 Patented Mar. 29, 1966 more usually several steps in series are provided, with a portion of the olefin reactant being admitted to each stage and .contacting isobutane passing serially through the successive stages. The alkylation feed which contains olefin reactant also contains isobutane, butylene, propane, propylene, and frequently small quantities of lighter parains. The temperature in the reaction zone is maintained at a constant low level by vaporizing therefrom the lighter components in the reaction products, more usually a mixture of butane, isobutane, propane, and any lower boiling compounds. Because of the high concentration of isobutane in the reactor liquid these vapors are predominantly isobutane. The vapors are compressed and condense-d, and the condensate after the removal of propane and the lighter components is returned to the alkylation reaction zone in the isobutane recycle. In addition or alternatively external mechanical or absorption refrigeration can be employed.

The alkylation mixture leaving the last reaction stage, comprising a mixture of alkylate, acid and unreacted hydrocarbons, passes into a `settling zone wherein contaminated acid catalyst, containing polymers and other impurities, is separated from the alkylate and unreacted isobutane. A portion of the contaminated acid is recycled to the contacting zone and the remainder is either purified for reuse, used in another process Where a high degree of purity is not required, or is discarded. Alkylate and unreacted isobutane are further processed to separate the alkylate, and the isobutane is recycled to the contacting zone.

Certain alkylation systems charge commercial mixtures of paratiins and commercial mixtures of olefins which consist primarily of parafins and oleiins having about 3-6 carbon atoms, for example propylene and/or propane, butenes and/or butanes, pentenes, and/or pentanes, hexanes and/ or hexenes, isomers thereof, etc.

In commercial processes of alkylation the ratio of isoparain to olefin is kept high in order to increase the alkylation of the olefin and to suppress polymerization of the olefin. Excess isoparafin is purified and separated after :alkylation and then recycled.

A representative commercial process of this type is shown in FIGURE I. In this process, after the separation of the acid, the hydrocarbon product is scrubbed with caustic and/ or water and the resulting product separated into alkylate and volatile fractions from which isobutane is recycled. Since large excesses of isobutane are employed, large separa-tion and distillation equipment must be employed which increases the cost of alkylation. Stated another way, because of the large excess of isoparafiin employed, it is necessary to recycle the isoparafiin to maximize yields. However, if the alkylation mixture is recycled without fully removing sulfuric acid from the hydro-carbon mixture, side reactions occur since reaction continues as long as sulfuric acid is present therein. Since separation is affected in -a typical commercial operation by gravitation, removal of the lacid from the hydrocarbon phase is slow and incomplete. In order to maximize the yield of desired product, contact time must Ibe short. In order to achieve this, it is necessary to remove sulfuric acid after the desired reaction time exposure is completed, such as by means of settling and caustic and/ or water scrubbing. Thereupon, the alkylate is separated from the volatile components `and isobutane is recycled. Because of the large excesses of isobutane employed, a large investment in separation and distillation equipment is required.

A disadvantage of such processing in the prior art is the requirement for massive volumes of catalyst; for example, the catalyst occupies 35-60% of the volume of the reactor. Since the catalyst in the case of sulfuric acid is not as effective when it becomes diluted to 90%, the industry is Eaced with a huge sulfuric Vacid disposal of regeneration problem which is both expensive and burdensome. Such massivevolurnes of catalyst require larger reaction vessels than would be employed if smaller amounts of catalyst could be employed. In addition, massive volumes of sulfuric acid tend to promote side reactions. Often the emulsions formed are hard to break upon completion `of Ithe reaction so that reaction contact time cannot be fully controlled.

-In application S.N. 174,735 to Samuelson there is described a method of alkylation which avoids the problems Iassociated with the use of massive volurnes of .alkylation catalyst and the absence of emulsion breaking control which comprises reacting an olen with an isoparafn lin the presence of a dispersed catalyst wherein the hydrocarbon phase is the continuous phase of said dispersion; and then subjecting the resulting product to an electric field. Samuelsons process uses substantially less acid by making a little acid ygo -a long way since the acid now -functions as a low volurne rather than as a massive volume catalyst. This is effected by finely dispersing catalytic amounts of -acid in the reaction medium, preferably in the isoparaffin so that the effective catalytic surface area of the acid, which effects reaction between the isoparafiin and the olefin, is maximize-d. However, the more dispersed the acid -the more difficult is the final separation of the Vacid from the reaction mixture since finely divided particles do not readily settle on standing. By employing an electric field in conjunction with these fine dispersions of acid, the reaction time is more readily cont-rolled since the application of an electric field, by

veffecting removal of the catalyst, stops the reaction and thus minimizes undesirable side reactions. In addition, rapid removal of the catalyst by the electric field decreases the time required to allow the catalyst 'to settle, permitting faster throughput. Thus, Samuelsons process permits the advantages of a finely dispersed catalyst without the disadvantages associated therewith since an electric field solves demulsification problems generally inherent in a system containing finely 'dispersed particles.

Thus, Samuelsons process (l) requires lesser volumes of sulfuric acid, (2) requires a smaller reactor, (3)r re- 'sults in fewer side reactions during alkylation, (4) reduces the disposal problem associated with larger volumes of spent sulfuric acid since lesser amounts of catalyst yield vgreater amounts of alkylate as compared to prior processes, ete-and facilitates demulsification upon completion of the reaction.

In its broadest aspects, Samuelsons invention relates to Vanalkylation process characterized by (1) a dispersion or emulsion of alkylation catalyst in the hydrocarbon phase so that a hydrocarbon continuous phase is rnaintainedfin the system and (2) the treatment of said Ahydrocarbon, continuous system with an electric field upon comple-tion of alkylation.

I have now discovered that by the use of an electric field the .alkylation mixture can be recycled lafter electrical treatment without -being purified as .in previous processes. In practice the .alkylation mixture after vbeing elec-trically treated to separate the acid, is proportioned sothat the major proportion thereof is directly recycled into the alkylation reactor and a minor proportion thereof is separated Iand fractionated in the conventional manner before returning isobutane lto the reaction. In this way capital investment in large and expensive. separation and distillation equipment is reduced since the `greater part of the hydrocarbon phase of the alkylation mixture is recycled without purification.

The essential differences Vbetween (l) the general processes of the prior art (FIGURE I) (2) the general process of Samuelson application S.N. 174,735 (FIGURE II) and (f3) the present invention (FIGURE III) are shown in the respective drawings specified above. The differences are as follows:

effected in the reactor, -as shown in FIGURE III.

(l) In the prior art processes, (a) the hydrocarbon layer is separated from the acid layer by 'gravity and (b) the hydrocarbon layer is not directly recycled to the reactor but is purified and separated such as by caustic and/or aqueous scrubbing, deisobutanizing, debutanizing, and depro-panizing prior to recycling the` isobutane into the reactor. In other words, the hydrocarbon phase of the alkylation mixture recycle of the present invention is omitted. Furthermore, the separator em-ployed in the prior art is a gravity separator.

(2) In the general process of Samuelson S.N. 174,735, the process is carried out in a manner similar to FIGURE I except that an [electrical separator is employed,

(3) The process of the present invention employs an electrical separator and an electrically treated alkylation EXAMPLE y In FIGURE III the isoparaiiin, such as isobutane, an

olefin such as isobutylene and 98% sulfuric acid are pumped into a reactor in metered proportions where the acid is finely dispersed in the isobutane-isobutylene phase. The reaction is carried out at 20 to 85 F., for example 35 to 70 F., but preferably 50 to 60 F. In practice temperatures of 50-55" F. are generally employed.

Dispers-ion of the catalyst in the hydrocarbon phase can be achieved by any suitable means such as for example circulating pumps, jet injectors, agitating and cir,- culating devices, etc., as well as more drastic dispersing means such as ultrasonics, colloidal mills, etc. High voltage electric fields can also be employed to create the emulsions or dispersions `Dispersions may be effected prior to entrance into the reactor vessel or they may be For example the acid can be emulsified or dispersed in the isoparafiin prior to entrance in the reaction vessel.

The agitation should be sufficient to produce a finely divided emulsion or dispersion which will be stable until itis desired to separate the hydrocarbon and catalyst phases at the conclusion of the reaction.V Increased agitation generally improves the results obtained, and vthe ultimate limit in this regard will be determined by economic considerations, in view of the power consumption required to improve agitation sufficiently to effect an improvement in yield or quality of the alkylate and the difiiculties which may be encountered in separating a very finely dividedand relatively stable emulsion. Since an electrostatic field can break -a tight emulsion, very fine dispersions can be used.

The temperature of the reaction is controlled by any desired means such as by precooling thereactants and acid and internal cooling in the reaction by the evaporation and recondensation of low boiling gas such as propane butane, and isobutane as shown in FIGURE III.

The molar ratio of isobutane to isobutylene should be in as large excessas possible s0 as to'rninim'ize side reactions,theoretically as high as 2000 or greater. However, in practice and because of economic considerations, ratios lower than such as from about l5 to a ratio of about 3, for example 10 to 5, but preferably aboutv 9 to 6 are employed.

Since a little acid goes a long way, and fine disper- -sions increase the surface area of the acid, relatively little acid as compared to the prior art process is employed, for example from about 3 to 50 volumes or more vof acid per 100 volumes -of hydrocarbon, advantageously 5 to 30 volumes, but preferably l0 to 20 volumes. However, regardless of volume ratios employed, the emulsion or dispersion formed should be hydrocarbon continuous, at least when in contact with the electric field.

` The alkylation reaction is initiated upon introduction of the sulfuric aci-d 4into the reactor. It is desirable to provide suiiicient agitation of the alkylation mixture in the reactor to maintain the acid catalyst in a fine state of subdivision most favorable, because of a large catature which is recycled :to that which is separated prior to recycling as isobutane is determined by practical considerations. Any desired ratio can be employed such as from about 100:1 or greater to about 1:100 or less,

lyst-isobutane surface area, to the alkylat-ion reaction. 5 such as from 70:1 to 10:1, for example from about 50:1 Such agitation can be provided by conventional mixing to 30:1, but preferably about 20:1. devices which employ internal or external recirculation, By directly recycling the electrically treated alkylation such as the stirrers shown in FIGURE III. mixture without further purification, smaller separation, The residence time :in the alkylation reactor is sufiipurification and distillation equipment are required thus cient to accomplish substantially complete conversion of resulting in a substantial reduction in capital investment the isobutylene to alkylate, generally not exceeding about and operational costs. 20-30 minutes and preferably not exceeding about 5-10 It should be noted that the emulsion need not be hyminutes, and most preferably not exceeding five mindrocarbon continuous during all stages of the process utes such as from1-4 minutes. but Should be hydrocarbon continuous when it enters From the alkylation reactor the alkylation mixture, the electric field. For example, the reaction mixture which now comprises alkylated product, unreacted hydromay be non-hydrocarbon continuous in the reactor but carbons, and acid materials, all in intimate admixture, is as it nears the electric field, the bulk of the acid may be now passed into the electric treater where it is subjected removed by a weak electric field at :the periphery of the to an electric field of sutiicient voltage to separate rapidelectric treating zone. Thereafter the emulsion entering ly the acid catalyst therefrom. Voltages capable of the electric treating area sh-ould be hydrocarbon corietiecting this will vary depending -on many variables. tinuous. Voltage gradients employed are in the range of about That part of product which has been proportionated l-50 kv., based 'on 1 inch electrode spacing, such as for the purification recycle enters the caustic scrubber about 5-25 kv./in., for example about 8-20 kv./in. but and/or water wash where the small amounts of acid preferably about 1015 kv./in. Both alternating and di- 25 remaining in the hydrocarbons are neutralized with rect currents can be employed, but preferably direct curaqueous alkali and/or water. The hydrocarbons, after rent. A wide variety of electric treaters can be embeing washed, enter the deisobutanizer wherein the unployed, for example those disclosed in U.S. Patent reacted hydrocarbons are separated from the alkylated 2,897,251,2,976,228 and elsewhere. products and butane by distillation. The lighter unre- By means of the electric field, the acid and hydroacted hydrocarbons pass to the depropanizer wherein carbons are separated into two phases, hydrocarbon propane is separated by distillation from isobutane. Iso- (upper) and acid (lower). The bulk of the -acid is rebutane is recycled into the reactor to which make-up turned to reactor while a portion of the acid is withisobutane is added. The heavier fraction from the dedrawn from the system as spent acid. isobutanizer is then :transferred to the debutanizer where- After leaving the electric separator, the hydrocarbon in n-butane is separated from alkylate. phase which is separated from the acid phase is pro- I have found that by employing a very effective elec- .portionated so that part th'eueof is directly recycled into trical treater in the process, the scrubber employing a the reactor and the remainder is treated so as to remove caustic and/or water wash may be omitted from the traces of residual acid from the product such as by process. In other words in certain instances where an means of a caustic scrubber and/oi water wa-sh. The 40 effective electric treater is employed scrubbing is optional. acid-free product is then deisobutanized, depropanized If desired an electric field can be employed to separate and debutanized to separate isobutane (which is recycled aqueous caustic or water from the hydrocarbons prior as shown in FIGURE III), propane, butane, and alkylto entering the deisobutanizer. ate. Data from specific runs carried out according to :this

The weight ratio of electrically treated alkylation mixinvention are presented in the following table:

Example Run Conditions:

(1) Isobutane Rate, ml./min 60 40 60 (2) Olen Rate, ml./1nin 20 20 20 (3g Olefin Feed, Type Butenes Butcnes Butenes (4 Acid, Total Vol. percent of Emulsion 12.0 12.0 (5) A`cid,Fresh Acid Concentration, wt. percent 99.7 99.3 99.3 (6) Acid, Ratio Recycle/Fresh Acid 8.7 7.4 7.4 (7) Contact Time, Emulsion Recycle, m 1. 5 1. 5 1. 5 (8) Mixer Outlet Temperature, F 68 66 73 (9) Emulsion Recycle Temperature, F 59 55 61 (10) Treater Outlet Temperature, Fm.. 48 43 48 (11) Treater Outlet Pressure, p.s.i.g 38 40 40 (12) Alkylation Mixture Recycle Rate, ml./min.

(After electric treatment) 400 360 360 Materials Summary:

l) Isobutane Charged, gms. 6,946 4,040 5, 2) Butenes Charged, g'ms 1, 589 1, 560 1, 220 (3) Alkylate Produced, ml 3,884 3,856 2,826 (4) Ratio, Alkylate/Olen Ch 1.7 1.7 1. 6 5) Ratio,1b.Aeid/ga1.A1ky1ate 0.44 0. 38 0. 23 (6) Yield, Distill. to 400 F. end point- 93 91. 7 92. 8 (7) Molar Ratio, iso C4/olefin, external 2. 73 1. 86 2.86 (8) Molar Ratio, iso (D4/olefin, recycle 10. 3 8.0 11. 6 Analytical Data: Alkylate:

(1) Specific Gravity at 60 F .6986 6950 697 (2) Refractive Index at 25 C 1.3950 1. 3958 1.3951 (3) Brornine Number 1.2 0.9 0.9 (4) Residue at 400 F. Vol. percent 3.5 4.0 3.4 (5) Isopentane Content, wt. percent. 6.3 7.3 5.0 (6) Ratio TMP/DMH =trimethyl pentane;

dimethylhexane 6. 7 5. 6 5. 7 (7) Octane Rating F-l Research 91.5 90. 7 92.0 Acid Sludge:

(l) Neutral Oils, Vol. percent 12 16 16 (2) Total Titratable Acidity, wt. percent 96.5 87.3 89.9

The present invention is particularly applicable to the alkylation of isobutane with C3, C4, or C5 olelins, or

propylene, butylenes, pentylenes, hexylenes, other higherV boiling monomeric oleiins or certain selected fractions of cracked naphthas, oleiin polymers Such as di-isobutylene, :tri-isobutylene, co-polymers, of isobutylene and .normal butylene such as the co-dirner, and various mixed polymers.

While the present invention has been described above as applying particularly to the use of sulfuric acid as catalyst, it is to be understood that any other suitable and conventional alkylation catalyst can be employed, such as hydroiiuoric acid, phosphoric acid, aluminum chloride-hydrocarbon complex, BF3.H2O, chlorosulfonic acid, fluorsulfonic acid and the like. The operating conditions for these catalysts are well-known, and conventional conditions coupled with the features of the present invention as set forth above may be used.

Moreover, the present invention is applicable to the alkylation of any organic compound having a readily replaceable hydrogen atom with any suitable alkylating agent. As stated above, the invention is of particular importance in the alkylation of an isoparafn or other parafn hydrocarbon having a tertiary carbon atom in the molecule, to enable a superior quality to be produced in large capacity. But the principles of the present invention are applicable to the alkylation of aV normal paraiin, a naphthene or cycloparaiiin, and an aromatic hydrocarbon, as well as or instead of the isoparafin. In place of an olefin as the alkylating agent, various alkyl esters, such as :the sulfates, chlorides, uorides, etc. may be used. For example, the' present invention can be employed in a two-stage absorption-alkylation process, wherein the oleiin is absorbed in acid in the first stage to produce the corresponding alkyl ester, and the ester either in solution in the absorbing acid or after separation therefrom as by isobutane or alkylate extraction, is then alkylated in the second stage in accordance with the present invention. Moreover, various aliphatic alcohols and ethers which are capable of forming oletins on reaction, such as tertiary butyl alcohol, isopropyl alcohol,V butyl ether, etc. may be employed as the alkylating agent, particularly with catalysts which have tolerance for water liberated in the reaction.

The term alkylatable compound relates to any organic compound having a replaceable hydrogen atom which can be alkylated with an oleiin or other suitable alkylating agent. The term alkylating agent relates to a material such as an olefin or its equivalent which is capable of alkylating said alkylatable compound. The term alkylation catalyst refers to an agent capable of effecting reaction between the alkylating agent and the alkylatable compound. The term alkylation mixture '8 refers to :the reaction product followingalkylation. reaction may be summarized as follows:

The

alkylating alkylate compound It is not intended that this inventiony be limited to the specific embodiments presented and described herein as many modications thereof are possible without departing from the scope and spirit of the invention. The principle `of this invention wherein an electric iield is applied to an oil continuous dispersion of an alkylation catalyst in the alkylation mixture and the recycling of the alkylation mixture after electric treatmen-t is applicable generally to the broad scope of the alkylation reaction.

Having thus described my invention, what I claim as new and desire to obtain by Letters Patent is:

1. A process of alkylation which is characterized by forming a hydrocarbon continuous dispersion of an alkylation` catalyst in an alkylationmixture, subjecting said hydrocarbon continuous dispersion of an alkylation catalystin the alkylation mixture to anelectric field, said electric field simultaneously causing rapid removal of said catalyst and stoppage of said alkylation process, said alkylation process continuing until said simultaneous rapid removal and stoppage by said electric field, said process minimizing undesirablefside reactions and permitting fasterv throughput, and recycling the electrically treatedalkylation mixture.

2. The process of claim 1 where the alkylation catalyst is sulfuric acid. l A 3. The process of claim 1 wherein the alkylation mixture contains isoparaiiin as the alkylatable compound and an oleiin as the` alkylating agent.

4'. The process of claim 3 wherein the alkylation catalyst is sulfuric acid.

5. The process 'of claim 3 wherein the isoparaiiin is isobutane and the oleiin is isobutylene.

6. The process of claim 5 wherein the alkylation catalyst is sulfuric acid. 7. The process of claim 1 wherein the alkylation mixture is acomrnercial mixture of paraflins as the alkylatable compounds and a commercial mixture of oleiins as the alkylating agents, each of said paraiiins and each of said oleiins having 3-6 carbon atoms.

A8. The process of claim 7 wherein the alkylation catalyst is sulfuric acid.

No references cited.

y ALLEN B. CURTIS, Primary Examiner.

i WINSTON A. DOUGLAS, Examiner.

B. J. OHLENDORF, Assistant Examiner. 

1. A PROCESS OF ALKYLATION WHICH IS CHARACTERIZED BY FORMING A HYDROCARBON CONTINUOUS DISPERSION OF AN ALKYLATION CATALYST IN AN ALKYLATION MIXTURE, SUBJECTING SAID HYDROCARBON CONTINUOUS DISPERSION OF AN ALKYLATION CATALYST IN THE ALKYLATION MIXTURE TO AN ELECTRIC FIELD, SAID ELECTRIC FIELD SIMULTANEOUSLY CAUSING RAPID REMOVAL OF SAID CATALYST AND STOPPAGE OF SAID ALKYLATION PROCESS, SAID 